Stretch breathable protective absorbent article using bilaminate

ABSTRACT

A disposable absorbent article of a brief or pull-up type incorporates a breathable laminate material composed of two layers. The laminate is an elastic material and may include non-elastic portions created by deactivating the material. The laminate material may be made breathable by the ultrasonic bonding process used to create the laminate. A third layer is adhered or bonded to the laminate and with leg elastics positioned between the laminate that the third layer. The absorbent article includes an absorbent assembly that overlaps with the non-elastic portions of the laminate.

This application is a continuation-in-part of commonly owned U.S. patentapplication Ser. No. 14/257,481 (filed Apr. 21, 2014), which isincorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates a disposable absorbent article in anunderwear or pull-up style. More particularly, the invention relates toprotective underwear that makes use of breathable laminate materialhaving two layers.

BACKGROUND OF THE INVENTION

Millions of people of all ages suffer from incontinence of the bowel orbladder. Whether an infant, adult, or elderly person, the underlyingcause of incontinence varies but the method of treatment typicallyinvolves use of absorbent article products. Adult incontinent briefs,disposable diapers and underpads can alleviate some of the emotional andphysical discomfort of incontinence by absorbing and containing liquidand other discharges from the human body to prevent body and clothingsoiling.

A disadvantage of known disposable undergarments is that they are oftenconstructed from materials that are designed to capture urine and otherexudates and prevent leakage, but are not breathable. Consequently,moisture may become trapped between the wearer and the disposableundergarment leading to discomfort and irritation. Further, asdisposable undergarments are intended to replace traditionalundergarments, disposable undergarments must be constructed to permitthe wearer to be repeatedly put-on and pull-off the garment as necessaryuntil such time as the garment is ready for disposal.

Disposable protective underwear products are known in the art. Suchdisposable underwear products rely on retractive forces that areprovided by elastics, such as spandex strands. It is also known to usestretch elastic laminates that replace the spandex strands so as toprovide better a fit to the wearer and improved discretion. Someproducts are created from a co-extruded elastic layer made during thenonwoven manufacturing process to provide a product with improvedbreathability.

Widlund, et al., U.S. Pat. No. 6,375,646 teaches a disposable diaperincluding an elongated absorbent pad, inner and outer casing layers andan elastically stretchable region in at least one of the front and backportions of the disposable diaper. The crotch portion of the disposablediaper is not stretchable. The combined stretchable and non-stretchableregions are designed to hold the absorbent material against the wearer'sbody to prevent leakage.

Norrby, et al., U.S. Pat. No. 8,298,205 teaches an elasticallystretchable laminate that includes a first non-elastic nonwoven web, asecond non-elastic nonwoven web and an elastic film between the firstand the second nonwoven webs. The laminate is rendered elastic in afirst direction by incremental stretching and partial tearing of thefirst and second nonwoven webs.

Thorson, et al., U.S. Patent Application Publication No. 2011/0098668,teaches a disposable absorbent garment employing elastomeric filmlaminate body panels. The laminate can include an elastomeric film andnonwoven layers, and inner and outer surfaces adhered to nonwoven andelastomeric film layers.

Stablefeldt, et al., U.S. Patent Application Publication No.2010/0168705, teaches disposable absorbent garments employingelastomeric film laminates with deactivated regions. A portion of thedisposable garment includes laminated elastomeric and non-elastomericpolymeric film layers and a nonwoven layer. An absorbent member extendspartially through the laminated layers.

Gilgenback U.S. Patent Application Publication No. 2010/0163161 teachesa process for making disposable absorbent garments employing elastomericfilm laminates with deactivated regions. A portion of the disposablegarment includes laminated elastomeric and non-elastomeric polymericfilm layers and a nonwoven layer. An absorbent member extends partiallythrough the laminated layers.

Kielpikowski, et al., U.S. Pat. No. 4,842,596, teaches a method formaking a breathable elastic fabric composite and personal articleincorporating same. A liquid impermeable elastomeric film is sandwichedbetween pairs of nonwoven sheets. The elastomeric film is a partiallystretched condition and bonded to the nonwoven sheets. The resultinglaminated sheets create gathers that form breathable apertures.

Klemp, et al., U.S. Pat. No. 6,994,761 teaches a disposable diaper andprocess for making the same. The diaper includes inner and outerportions that are ultrasonically bonded to create the vent sites orapertures through a layer of stretchable, breathable material.

BRIEF DESCRIPTION OF THE FIGURES

Advantages of the invention will become apparent upon reading thefollowing detailed description and upon reference to the drawings.

FIG. 1 is a top plan view of laminate portions of an absorbent articlein a substantially flat un-contracted position according to anembodiment of the invention.

FIG. 2 is a cross-sectional view of the laminate of FIG. 1 alongsectional line A-A.

FIG. 3 is a cross-sectional view of a breathable laminate according toan embodiment of the invention.

FIG. 4 is a top view of the laminate of FIG. 3.

FIG. 5 is a top plan view of an embodiment of the absorbent article ofFIG. 1 in a substantially flat un-contracted position and furtherincluding leg and waist elastics.

FIG. 6 is an alternative embodiment of the absorbent article of FIG. 5.

FIG. 7 is a top plan view of an embodiment of the absorbent article ofFIG. 1 in a substantially flat un-contracted position and furtherincluding a covering nonwoven layer.

FIG. 8 is a cross-sectional view of the absorbent article of FIG. 7along sectional line B-B.

FIG. 9 is a cross-sectional view of an embodiment of a laminate used ina portion of the absorbent article illustrated in FIG. 7.

FIG. 10 is a cross-sectional view of an embodiment of a laminate used ina further portion of the absorbent article illustrated in FIG. 7.

FIG. 11 is a top plan view of an embodiment of the absorbent article ofFIG. 1 in a substantially flat un-contracted position and furtherincluding an absorbent assembly.

FIG. 12 is an exploded perspective view of an embodiment of theabsorbent article of FIG. 11.

FIG. 13 is a cross-sectional view of a breathable laminate for use in afurther embodiment of the invention.

FIG. 14 is a top view of the laminate of FIG. 13.

DETAILED DESCRIPTION

Absorbent articles as described herein generally include amoisture-pervious inner layer, an absorbent layer, and amoisture-impervious outer layer. Although the remainder of thedescription will be specifically directed to adult incontinencearticles, such as disposable diapers or briefs, it is to be understoodthat the embodiments may also be implemented using other absorbentarticles and that the properties and uses described below apply to theseother absorbent articles as well. Throughout this application, the termsabsorbent article, diaper or brief are used interchangeably. However, itshould be understood that the terms diaper or brief are intended toinclude other absorbent articles, such as training pants, incontinencepads, etc., as would be understood by one of ordinary skill in the art.

As used in the description herein and throughout the claims, thefollowing terms take the meanings explicitly associated herein, unlessthe context clearly dictates otherwise: the meaning of “a,” “an,” and“the” includes plural reference, the meaning of “in” includes “in” and“on.” Relational terms such as first and second, top and bottom,proximal and distal, and the like may be used solely to distinguish oneentity or action from another entity or action without necessarilyrequiring or implying any actual such relationship or order between suchentities or actions.

As used herein, the following terms have the following meanings:

“Attach” and its derivatives refer to the joining, adhering, connecting,bonding, sewing together, or the like, of two elements. Two elementswill be considered to be attached together when they are integral withone another or attached directly to one another or indirectly to oneanother, such as when each is directly attached to intermediateelements. “Attach” and its derivatives include permanent, releasable, orrefastenable attachment. In addition, the attachment can be completedeither during the manufacturing process or by the end user.

“Bond” and its derivatives refer to the joining, adhering, connecting,attaching, sewing together, or the like, of two elements. Two elementswill be considered to be bonded together when they are bonded directlyto one another or indirectly to one another, such as when each isdirectly bonded to intermediate elements. “Bond” and its derivativesinclude permanent, releasable, or refastenable bonding.

“Connect” and its derivatives refer to the joining, adhering, bonding,attaching, sewing together, or the like, of two elements. Two elementswill be considered to be connected together when they are connecteddirectly to one another or indirectly to one another, such as when eachis directly connected to intermediate elements. “Connect” and itsderivatives include permanent, releasable, or refastenable connection.In addition, the connecting can be completed either during themanufacturing process or by the end user.

“Breathable” when used in describing a layer or multi-layer laminatemeans that the layer has the ability to allow moisture vapor to betransmitted through the material. Breathable layers may be airpermeable, but it is not necessary to be air permeable to be breathable.In addition, breathable layers may be liquid permeable or liquidimpermeable.

“Disposable” refers to articles that are designed to be discarded aftera limited use rather than being laundered or otherwise restored forreuse.

The terms “disposed on,” “disposed along,” “disposed with,” or “disposedtoward” and variations thereof are intended to mean that one element canbe integral with another element, or that one element can be a separatestructure bonded to or placed with or placed near another element.

“Fiber” refers to a continuous or discontinuous member having a highratio of length to diameter or width. Thus, a fiber may be a filament, athread, a strand, a yarn, or any other member or combination of thesemembers.

“Layer” when used in the singular can have the dual meaning of a singleelement or a plurality of elements.

“Liquid impermeable,” when used in describing a layer or multi-layerlaminate means that liquid, such as urine, will not pass through thelayer or laminate, under ordinary use conditions, in a directiongenerally perpendicular to the plane of the layer or laminate at thepoint of liquid contact.

“Liquid permeable” refers to any material that is not liquidimpermeable.

“Member” when used in the singular can have the dual meaning of a singleelement or a plurality of elements.

“Nonwoven” and “nonwoven web” refer to materials and webs of materialthat are formed without the aid of a textile weaving or knittingprocess. For example, nonwoven materials, fabrics or webs have beenformed from many processes such as meltblowing processes, spunbondingprocesses, air laying processes, and bonded carded web processes.

These terms may be defined with additional language elsewhere in thespecification.

FIGS. 1, 5-7 and 9 illustrate a plan view of the absorbent article 10 ina substantially flat un-contracted state. As shown in these figures, theabsorbent article 10 generally consists of several layers, including aninner layer, an absorbent layer, and an outer layer. The inner layerfaces a wearer and contacts the skin of the wearer when the absorbentarticle 10 is secured to the wearer. The inner layer may comprise atopsheet that is composed of a moisture-pervious fabric suitable toallow bodily discharge to pass through the inner layer and be absorbedby the absorbent layer. Non-limiting examples of materials suitable toform the topsheet include polypropylene, polyethylene, polyester,materials having hydrophobic properties, combinations thereof and/or thelike. Additionally, the topsheet can be treated with a hydrophilicfinish to improve pass through of liquids to diaper layers beneath theinner layer. Non-limiting examples of suitable hydrophilic finishesinclude stearic acid, melamine-based chemicals, fluorocarbon chemicals,and silicon based chemicals.

The plan view of FIGS. 1, 5-7 and 9 is shown from the top or patientcontacting side of the absorbent article. As illustrated in thesefigures, a particular embodiment of a disposable absorbent article 10 ofthe present invention defines a longitudinal direction 21 parallel to acenterline CL and a transverse direction 22 perpendicular to thelongitudinal direction. The absorbent article comprises a front section12, a rear section 16, and a crotch section 14.

Referring to FIG. 1, the absorbent article includes a film layer 24comprising a laminate film. The laminate film may be divided into twosections such that the film layer 24 forms at least part of the frontsection 12 and rear section 16. The front film section 30 is spacedapart from the rear film section 32 such that they are separated in thecrotch section 14.

The front film section 30 defines a front end edge 26 and a front crotchedge 27 parallel to and longitudinally spaced from the front end edge26. The rear film section 32 defines a rear end edge 28 longitudinallyopposite the front end edge 26 and a rear crotch edge 29 parallel to andlongitudinally spaced from the rear end edge 28. The front film sectiondefines opposed front leg edges 34 and 36, and the rear film sectiondefines opposed rear leg edges 36 and 38.

The front film section 30 further defines first and second transverselyopposed front side edges 42 and 44. The first front side edge 42 extendsin the longitudinal direction 21 from the front end edge 26 to a frontintersection point 46 where the first front side edge intersects thefirst front leg edge 34. The second front side edge 44 extends in thelongitudinal direction 21 from the front end edge 26 to a frontintersection point 48 where the first front side edge intersects thesecond front leg edge 36. The rear film section 32 also defines firstand second transversely opposed back side edges 50 and 52. The firstback side edge 50 extends in the longitudinal direction 21 from the backend edge 28 to a rear intersection point 54 where the first rear sideedge 50 intersects the first rear leg edge 38, and the second back sideedge 52 extends in the longitudinal direction 21 from the back end edge28 to a rear intersection point 56 where the second rear side edge 52intersects the second rear leg edge 40.

In particular embodiments, the front section 30 is constructed at leastin part of a laminate 24 that comprises a polymeric film layer 62 and atleast one nonwoven layer 60 (FIG. 2), wherein both the polymeric filmlayer 62 and the nonwoven layer 60 extend substantially throughout thearea of the laminate 24.

In its completed form as used by a wearer, the absorbent articleincludes a first side seam at which the first front side edge 42 isattached to the first back side edge 50 and which defines a first sideseam length. The article further includes a second side seam at whichthe second front side edge 44 is attached to the second back side edge52 and which defines a second side seam length. The article isaccordingly formed into a brief or pull-up style disposable absorbentarticle.

FIG. 2 shows a cross-sectional view of the laminate 24 along line A-A.In one embodiment, the laminate 24 comprises a first nonwoven layer 58superposed on the bottom surface of the polymeric film 62 such that thepolymeric film 62 and the first nonwoven layer 58 extend substantiallythrough the area of the laminate 24. The polymeric film layer may be ablock copolymer. A portion 64 of the bottom or outer layer of nonwoven58 may extend beyond the polymeric film 62 along front end edge 26. Afurther portion 66 of the bottom or outer layer of nonwoven 58 mayextend beyond the polymeric film 62 along rear end edge 28.

As shown in FIGS. 3-4, the laminate 24 may be formed of a breathablecloth-like elastic nonwoven laminar fabric by attaching a liquidimpermeable and non-self-adhering elastomeric film or nonwoven carriersheet 110 to a nonwoven facing sheet 114 and bonding the facing sheet114 and elastomeric film 110 together by autogenous bonds, such asultrasonically or thermally-generated bonds at spaced apart sites 116,thereby forming breathable apertures 120 through the carrier sheet whichlaminate the carrier and facing sheet together at the spaced apart sites116.

In an embodiment of the present invention, the facing sheet 114 and theelastomeric film 110 are ultrasonically bonded at sites 116. Theultrasonic bonding process creates a bond region 122 where the materialfrom the facing sheet 114 and elastomeric film 110 mix together to forma bond. The ultrasonic bonding process may be configured such that itgenerates a through passage 120 generally within the confines of thebond region 122 in order to provide for the passage of water vapor 118and give breathability to the laminate 24.

In an alternative embodiment as illustrated in FIGS. 13-14, the facingsheet 214 and the elastomeric film 210 are ultrasonically bonded atsites 216. The ultrasonic bonding process creates a bond region 222where the material from the facing sheet 214 and elastomeric film 210mix together to form a bond. The ultrasonic bonding process may beconducted while the sheet is moving in a direction 224 such that atrailing tear 226 forms in the laminate generally outside and adjacentto the bond region 222. These trailing tears 226 provide throughopenings for the passage of water vapor 118 and give breathability tothe laminate 24. While the bond regions 222 and trailing tears 226 areshown in FIGS. 13-14 as being of a size and shape sufficiently large toillustrate the structure of the bonded laminate, one of skill in the artwill understand that these may be of any appropriate size and shape andmay be sufficiently small that they are not be readily apparent withoutthe use of magnification.

Alternatively, the laminate 24 can also be constructed such that the webis not made breathable during the ultrasonic laminating process, butrather has breathability imparted through a needling, slitting or dietreatment process after formation of the complete laminate.

Referring again to FIG. 1, at least a portion 68 of the front filmsection 30 is non-elastomeric, and at least a portion 70 of the rearfilm section 32 is non-elastomeric. In FIGS. 1, 5-7 and 9non-elastomeric or partially elastomeric regions are indicated by apattern of hash lines, which lines are continuous if the non-elastomericregions are exposed, and which lines are dashed if the non-elastomericregions are concealed by an overlying component. In one preferredapproach, as shall be described in more detail below, the entirelaminate 24 is constructed of an elastomeric film laminate whichincludes an elastomeric film layer and at least one nonwoven facinglayer, and a portion of the laminate has been “deactivated” or“deadened” to render it non-elastomeric.

As used herein, “elastomeric” refers to a material or composite whichcan be elongated by at least 50 percent of its relaxed length and whichwill recover, upon release of the applied force, at least 50 percent ofits elongation. It is generally preferred that the elastomeric materialor composite be capable of being elongated by at least 100 percent, morepreferably by at least 200 percent, of its relaxed length and recover,upon release of an applied force, at least 50 percent of its elongation.“Non-elastomeric” refers to a material or composite that isnon-extensible, or that is extensible but will recover no more than 20percent of its elongated length after release of an applied elongatingforce. “Non-extensible” refers to a material that cannot stretch orextend by more than 25 percent of its relaxed length without fractureupon application of a biasing force. “Partially elastomeric” refers to amaterial or composite which can be elongated by at least 50 percent ofits relaxed length and which will recover, upon release of the appliedforce, more than 20 percent but less than 50 percent of its elongation.

“Deactivated” as used herein to describe a material, region of amaterial, or regions of a material means that the material, region, orregions of material has been treated in some way to substantiallydestroy the elastic properties of the material, region, or regions,rendering the material, region, or regions non-elastomeric.

Deactivation of the non-elastic portions 68, 70 may be accomplished by adeactivation unit to create deactivated regions in the elastomeric filmlaminate 24. The deactivation can be accomplished by any of a variety ofmeans. Frequently, some form of energy is applied to deactivate thenon-elastic regions 68, 70, such as pressure, heat, ultrasonic energy,combinations thereof, and the like. Techniques employing pressure, heat,and ultrasonic energy are known in the art. The deactivation can occurin a variety of patterns. For example, the deactivating energy could beapplied in a solid pattern, a series of vertical stripes, horizontalstripes, or diagonal stripes, a series of squares or dots, or othersuitable pattern.

In embodiments of the present invention as illustrated in FIG. 5, theabsorbent article 10 comprises a first rear leg elastic member 80attached to an inside surface of the rear film section 32 adjacent atleast a portion of the first rear leg edge 38, and a second back legelastic member 82 to an inside surface of the rear film section 32adjacent at least a portion of the second rear leg edge 40. In furtherembodiments, the absorbent article 10 comprises a first front legelastic member 84 attached to an inside surface of the rear film section30 adjacent at least a portion of the first front leg edge 34, and asecond front leg elastic member 86 attached to attached to an insidesurface of the rear film section 30 adjacent at least a portion of thesecond front leg edge 36. Each leg elastic member 80, 82, 84, 86 cancomprise a single strand, ribbon, or strip of elastomeric material, oreach can comprise two or more strands, ribbons, or strips, such as, forexample, three strands (as depicted in FIG. 5). The leg elastic members80, 82, 84, 86 may be glued in place or otherwise adhered to a topsurface of nonwoven layer 60.

As illustrated in FIG. 5, rear leg elastic member 80, 82 may extend fromside edges 50, 52 of the rear film section 32 along rear leg edges 38,40 to side edges of the non-elastic portion 70 of the rear film section.Alternatively, the rear leg elastic member 80, 82 may extend across partor the entire non-elastic portion 70. Likewise, front leg elastic member84, 86 may extend from side edges 42, 44 of the front film section 30along front leg edges 34, 36 to side edges of the non-elastic portion 68of the front film section. Alternatively, the front leg elastic member84, 86 may extend across part or the entire non-elastic portion 68.

For example, the first rear leg elastic member 80 and the second rearleg elastic member 82 may form part of a single, integral back elasticmember that extends from the first rear side edge 50 transversely overthe non-elastic portion 70 to the second rear side edge 52. Similarly,in certain embodiments, the first front leg elastic member 84 and thesecond front leg elastic member 86 form part of a single, integral frontelastic member that extends from the first front side edge 42transversely over the non-elastic portion 68 to the second front sideedge 44.

In embodiments, as illustrated in FIG. 5, the extension 64 of the outernonwoven layer 58 (see FIGS. 1-2) of the front portion 30 may be foldedover the top of inner nonwoven layer 60 to define the front end edge 26.A similar extension 63 of the outer layer of nonwoven of the rearlaminate 32 may be folded over the top of inner nonwoven layer to definethe rear end edge 28.

The absorbent article 10 may further include a front waist elasticmember 98 positioned within the front fold 64 and a back waist elasticmember 102 positioned within the back fold 63. In alternativeembodiments, no front waist fold or back waist fold is included; in suchembodiments, opposite end edges of the laminate sections 30, 32 woulddefine the front end edge 26 and back end edge 28, respectively. Eachwaist elastic member 98, 102 may comprise a single strand, ribbon, orstrip of elastomeric material, or each can comprise two or more strands,ribbons, or strips.

FIG. 6 illustrates further embodiments in which the leg elastic members180, 182, 184, 186 comprises a series of elastic strands. Theillustrated embodiment shows three such strands, but more or fewerstrands may be used. The leg elastics may be applied in a curvedfashion. At the side edges 42, 44, 50, 52 of the diaper, the legelastics are generally parallel, and each of the independent legelastics are then curved towards the respective non-elastic portions 68,70 of the film sections 30, 32, and increasingly separated in distancefrom one another the closer the leg elastics get to the non-elastic filmportions. Also as shown in FIG. 6, the waist elastic members 198, 202may comprise multiple elastic strands.

As illustrated in FIGS. 7-8, an additional covering nonwoven layer 104may be attached to a top surface of the polymeric film layer 62 thatcomprises the top layer of the front laminate section 30. Additionally,a further covering nonwoven layer 106 may be attached to a top surfaceof the polymeric film layer 62 that comprises the top layer of the rearlaminate section 32. The covering nonwoven layers 104, 106 are placed ontop of laminate sections so that they at least in part cover the legelastic elements. The covering nonwoven layers may be bonded to the filmlaminate 24 in the region 105 where the leg elastics 80, 82, 84, 86 arenot present and may be glued to the elastics and/or the polymeric filmlayer 62 in region 107 where the elastics are located.

The front 30 and rear 32 laminate sections may each be separated intotwo or more areas that are characterized by the manner in which thecovering nonwoven layers 104, 106 are attached to the polymeric filmlayer 62. The front section 30 may have a first bonded portion 105 inwhich the covering nonwoven 104 is attached to the film laminate 24 byautogenous bonds, such as ultrasonically or thermally-generated bonds atspaced apart sites. The rear section 32 may have a corresponding bondedportion 109.

As illustrated in FIG. 9, the spaced apart bonding sites 316 of areas105 form breathable apertures 320 through the outer nonwoven layer 358,polymeric film layer 362 and covering nonwoven layer 304. The ultrasonicbonding process creates a bond region 322 where the material from theouter facing sheet 358, polymeric film 362 and inner facing sheet 304mix together to form a bond. The ultrasonic bonding process may beconfigured such that it generates a through passage 320 generally withinthe confines of the bond region 322 in order to provide for the passageof water vapor 118 and give breathability to the laminate 24. Thesebonding sites 316 may correspond to the boding sites 116 already presentin the laminate 24 (which consists of outer facing nonwoven sheet 358and polymeric film 362). Alternatively, the bonding sites 316 may be notalign to the existing bond sites 116 such that the bonding sites 316create new through passages 320 that pass through the three layers ofthe laminate. In some embodiments, this will result in previous bondsites 116 that are covered on the inside by the inner facing nonwovenlayer 304. The inner facing layer 304 may be a breathable nonwovenmaterial such that water vapor 118 may pass through previous bond sites116 even though those bond sites are now covered by the inner facinglayer 304.

Referring again to FIG. 7, the front section 30 may have a secondadhered portion 107 in which the covering nonwoven 104 is attached tothe film laminate 24 by an adhesive or lamination process. The rearsection 32 may have a corresponding adhered portion 111.

As shown in FIG. 10, the covering nonwoven 304 may be attached to thepolymeric layer 362 by application of an adhesive material 363. Thisadhesive may in a manner, such that it does not block some or all of theexisting through passages 120. For example, the adhesive may be appliedin a pattern such that it is applied to some of the through passages120, but not others. Alternatively, the adhesive may be of a type orapplied in such a manner that it does not fill or seal the existingthrough passages 120. Accordingly, provided that the inner facing layer304 is a breathable material, water vapor 118 may pass through previousbond sites 116 even though those bond sites are now covered by the innerfacing layer 304, and the breathability of these areas 107, 111 will bepreserved.

The differently adhered areas 105, 107 of the front section 30 may beseparated by a line 332 that runs transversely across the width of theabsorbent article such that the upper waist area of the article fallgenerally within the first area 105 while the lower waist area and legelastics 84, 86 fall generally within the second area 107.Alternatively, the differently adhered areas may be separated by a line334 that more closely follows the contours of the leg elastics such thatmore of the waist area falls within the first area 105. Likewise, thedifferently adhered areas 109, 111 of the rear section 32 may beseparated by a generally straight transverse line 336 or a morecontoured line 338. It should be understood that the line separatingthese sections can be positioned and contoured as would be understood byone of skill in the art in order to performance, cost and otherattributes of the absorbent article.

As illustrated in FIGS. 11-12, the absorbent article 10 also includes anabsorbent assembly 148 that extends from the front section 12, acrossthe crotch section 14, to the rear section 16. The absorbent assemblyincludes an absorbent core 152, and may include a topsheet 154 and abacksheet 150. (The topsheet 154 has been removed in FIG. 11 to moreclearly show the position of the backsheet 150 and absorbent core 152.)The absorbent assembly 148 may be generally rectangular as shown in FIG.11 or may comprise curved sections 166 to accommodate the wearer's legsas shown in FIG. 12. The absorbent core 152 may have an area that issmaller than the topsheet 154 and backsheet 150 such that the absorbentcore is contained within the periphery of the absorbent assembly. Thetopsheet 154 and backsheet 150 may be bonded or otherwise adhered arounda periphery of the absorbent assembly in order to capture the absorbentcore 152 between the two sheets.

As shown in FIG. 11, the absorbent assembly 148 overlaps with the frontsection 30 to form a front overlapping zone 156, and the absorbentassembly 148 overlaps with the rear section 32 to form a rearoverlapping zone 158. The periphery of the absorbent core 152 may bepositioned completely within the front non-elastic portion 68 where thecore overlaps with the front film section 30 and positioned completelywithin the rear non-elastic portion 70 where the core overlaps with thefront film section 32. The backsheet 150 and topsheet (not shown) mayalso be positioned within the non-elastic portions 68, 70 in theoverlapping zones, or may extend beyond the non-elastic portions asillustrated in FIG. 11.

In embodiments of the invention, the non-elastic portions 68, 70 mayencompass more than 50% of the respective overlapping zones 156, 158. Inother embodiments, more than 75%, and in further embodiments more than90% of the area of the overlapping zones 156, 158 are non-elastomeric.In further embodiments, the entire of the overlapping zones arenon-elastomeric. By adjusting the size of the non-elastic portions 68,70 relative to the size of the absorbent core 152, the fit range of thearticle may be adjusted or the shape of the absorbent assembly may bedefined in order to more readily capture exudate or prevent leaks.

In further embodiments, the non-elastic portions 68, 70 extend beyondthe periphery of the absorbent core 152 or even beyond the backsheet150. For example, non-elastic regions may be at least 10% larger, 20%larger, or in further embodiments 25% larger in area than the respectiveoverlapped regions 156, 158. Providing non-elastic portions that arelarger than their respective overlapping zones allows the process toaccommodate any registration variability that may be present in themanufacturing process.

While the present invention has been described with reference to one ormore particular embodiments, those skilled in the art will recognizethat many changes may be made thereto without departing from the spiritand scope of the present invention. Furthermore, components from oneembodiment can be used in other non-exclusive embodiments. Each of theseembodiments and obvious variations thereof is contemplated as fallingwithin the spirit and scope of the invention.

What is claimed is:
 1. An absorbent article, comprising: a frontlaminate section defining a front end edge, a front crotch edge parallelto and longitudinally spaced from the front end edge, and first andsecond transversely opposed side edges extending in a longitudinaldirections, the front laminate section comprising a front non-elasticportion adjacent to the front crotch edge, a front elastic portionadjacent to the front end edge, the front laminate section furthercomprising: a non-breathable polymeric film, a first nonwoven layer, aplurality of spaced apart ultrasonic bonding sites attaching the firstnonwoven layer to a first side of the polymeric film, a plurality ofbreathable apertures through the polymeric film, wherein the pluralityof breathable apertures consists of a series of through passages thatprovide for the passage of water vapor through the front laminate witheach through passage being formed in conjunction with one of theplurality of ultrasonic bonding sites, and a second nonwoven layerattached to a second side of the polymeric film opposite the firstnonwoven layer, wherein the second nonwoven layer is attached to thepolymeric film by a first adherence mechanism in a first zone and asecond adherence mechanism, different from the first adherencemechanism, in a second zone; a rear laminate section defining rear endedge, a rear crotch edge parallel to and longitudinally spaced from therear end edge, and first and second transversely opposed side edgesextending in a longitudinal directions, the rear laminate sectioncomprising a rear non-elastic portion adjacent to the rear crotch edgeand a rear elastic portion adjacent to the rear end edge; and anabsorbent assembly extending longitudinally between the front crotchedge and the rear crotch edge, the absorbent assembly comprising atopsheet, a back sheet and an absorbent core positioned between thetopsheet and backsheet.
 2. The absorbent article of claim 1 wherein theabsorbent assembly overlaps with the front non-elastic portion and therear non-elastic portion and does not overlap with the front elasticportion and the rear elastic portion.
 3. The absorbent article of claim1 wherein the front laminate section farther defines a first leg edge,and the absorbent article further comprises: a first leg elastic that isadhered to a surface of the front laminate section and extends paralleland adjacent to the leg edge from the side edge to an edge of the frontnon-elastic portion; and a second leg elastic that is adhered to asurface of the front laminate section and that is increasingly separatedin distance from first leg elastic as the leg elastics extend from theside edge to an edge of the front non-elastic portion.
 4. The absorbentarticle of claim 3 wherein the leg elastic is positioned between thepolymeric film and the second nonwoven layer.
 5. The absorbent articleof claim 1 wherein the polymeric film is an elastomeric film.
 6. Theabsorbent article of claim 5 wherein the non-elastic portion of thefront laminate is formed by deactivating a portion of the elastomericfilm.
 7. The absorbent article of claim 1 wherein the first adherencemechanism comprises a plurality of spaced apart bonding sites.
 8. Theabsorbent article of claim 7 wherein the bonding sites are ultrasonicbonds.
 9. The absorbent article of claim 1 wherein the second adherencemechanism comprises an adhesive material.
 10. The absorbent article ofclaim 9 wherein the leg elastics are positioned within the second zone.11. An absorbent article, comprising: a breathable front laminatesection defining front end edge, a front crotch edge parallel to andlongitudinally spaced from the front end edge, first and secondtransversely opposed side edges extending in a longitudinal directions,and first and second leg edges, the front laminate section comprising: anon-breathable polymeric film, a first nonwoven layer attached to afirst side of the polymeric film at a plurality of spaced apart bondingsites, a second nonwoven layer attached to a second side of thepolymeric film opposite the first nonwoven layer, wherein the secondnonwoven layer is attached to the polymeric film by a first adherencemechanism in a first zone and a second adherence mechanism differentfrom the first adherence mechanism, in a second zone, a frontnon-elastic portion adjacent to the front crotch edge, and a frontelastic portion adjacent to the front end edge, and a plurality ofbreathable apertures through the polymeric film, wherein the pluralityof breathable apertures consists of a series of through passages thatprovide for the passage of water vapor through the front laminate witheach through passage being formed in conjunction with one of theplurality of bonding sites; a rear laminate section defining rear endedge, a rear crotch edge parallel to and longitudinally spaced from therear end edge, first and second transversely opposed side edgesextending in a longitudinal directions, and first and second leg edges,the rear laminate section comprising a rear non-elastic portion adjacentto the rear crotch edge and a rear elastic portion adjacent to the rearend edge; and an absorbent assembly extending longitudinally between thefront crotch edge and the rear crotch edge, the absorbent assemblycomprising a topsheet, a back sheet and an absorbent core positionedbetween the topsheet and backsheet.
 12. The absorbent article of claim11 wherein the bonding sites are ultrasonic bonding sites.
 13. Theabsorbent article of claim 12 wherein the through passages are formedwithin a perimeter of the ultrasonic bonding site.
 14. The absorbentarticle of claim 12 wherein the through passages are tears formed in thepolymeric film with each tear being outside of and adjacent to aperimeter of the ultrasonic bonding site.
 15. The absorbent article ofclaim 11 wherein the front laminate section further defines a first legedge, and the absorbent article further comprises: a first leg elasticthat is adhered to a surface of the front laminate section and extendsparallel and adjacent to the leg edge from the side edge to an edge ofthe front non-elastic portion; and a second leg elastic that is adheredto a surface of the front laminate section and that is increasinglyseparated in distance from first leg elastic as the leg elastics extendfrom the side edge to an edge of the front non-elastic portion.
 16. Theabsorbent article of claim 1 wherein the through passages are formedwithin a perimeter of the ultrasonic bonding site.
 17. The absorbentarticle of claim 1 wherein the through passages are tears formed in thepolymeric film with each tear being outside of and adjacent to aperimeter of the ultrasonic bonding site.